Prototype & NPI Assembly

From Design to Working Board
in as Little as 24 Hours

Fast-turn prototype and NPI assembly with 1-piece minimum order, engineering DFM/DFA feedback and a direct bridge to mass production once your design is validated.

1-Piece MOQ 24–72h Turnaround Free DFM Review Mass-Production Ready
24h
Fastest assembly turnaround
1pc
Minimum order quantity
4h
DFM/BOM review turnaround
99%
First-pass assembly success rate
2500+
Prototype builds completed
24h
Express assembly option
1 pc
Minimum order quantity
NPI
Seamless bridge to production
Industries We Serve

Fast iteration for every
hardware team

From first proof-of-concept to pre-production validation, hover to see how we support each industry.

01

Automotive

Rapid ECU and sensor prototype builds with DFM feedback ahead of costly IATF 16949 production tooling.

02

Medical

First-article inspection and documented builds to support early design-verification testing for device startups.

03

Industrial

Low-volume pilot runs for control and automation hardware before committing to full production tooling.

04

Consumer Electronics

Rapid re-spins between crowdfunding demo, EVT and DVT builds without waiting on full-reel component orders.

05

Telecom & 5G

Fast-turn RF module prototypes to validate antenna and signal-chain designs before infrastructure-scale sourcing.

06

Aerospace & Defense

Documented first-article builds and rapid re-spin support for engineering evaluation units under NDA.

07

IoT & Smart Devices

1-piece MOQ assembly for connected-device startups iterating firmware and hardware in parallel sprints.

08

Energy & Power

Quick-turn power-converter prototypes to validate thermal and layout performance before a production run.

How It Works

From upload to working
board, without the wait

Every hour spent waiting on a prototype is an hour your product launch slips. Our process is built to compress that timeline.

01

File Upload & Instant Quote

Upload Gerbers and BOM for an instant online quote. Engineering and BOM review begins immediately — no waiting on a sales cycle to get a project moving.

Instant quote · 1-piece MOQ
02

Engineering DFM/DFA Review

Our engineers check footprints, panelization, part availability and assembly feasibility within 4 working hours, flagging issues before you commit to a build.

4h turnaround · free of charge
03

Expedited Fabrication & Rapid Component Sourcing

Boards move onto expedited fabrication lines while we source components in prototype quantities — including small-reel and cut-tape purchasing, so you're never forced to buy a full reel for a single build.

expedited fab · cut-tape sourcing
04

Assembly, First Article Inspection & Fast Ship

SMT/THT assembly is followed by a documented first-article inspection report, then same-day shipping. Need a re-spin? We rebuild within 24–48 hours using the same DFM data — and scale directly to production once your design is validated.

FAI included · 24–48h re-spin · bridge to production
Engineering & Sourcing Support

Built for speed and
design iteration

Prototype builds get the same engineering attention as production — just faster.

Design Review

DFM/DFA Feedback Within Hours

Our engineers review every prototype submission for manufacturability and assembly feasibility — footprint accuracy, component orientation, panelization and stack-up — with comments returned within 4 working hours, free of charge.

4h review turnaround free of charge footprint & DFA checks
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Component Sourcing

Flexible Low-MOQ Component Sourcing

Prototype quantities don't require full-reel purchasing. We source in small-reel and cut-tape formats where available, and flag any part with a minimum-buy conflict during the DFM stage — before it becomes a surprise cost.

cut-tape sourcing small-reel purchasing 1-piece build support
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Rapid Assembly

Same-Day to 72-Hour SMT + THT Assembly

Dedicated prototype assembly lines handle fine-pitch SMT placement and hand-soldered THT for boards that would otherwise queue behind production runs. Standard turnaround is 72 hours; a 24-hour express option is available for urgent builds.

24–72h turnaround dedicated prototype lines SMT + THT
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Scale-Up

A Seamless Bridge to Mass Production

Once your design is validated, we carry the same DFM data, approved BOM and process notes directly into a production quote — no re-review, no re-sourcing from scratch, and no need to switch suppliers between prototype and volume manufacturing.

shared DFM data no supplier switch volume requoting in 24h
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Technical Specifications

Prototype program
parameters.

Every parameter below applies from your very first prototype run — the same process controls carry through when you scale to production.

  • 1pc
    Minimum order quantity
  • 24h
    Fastest turnaround
  • 4h
    DFM/BOM review
  • 1-20L
    Layer count range
Request Capability Sheet →
ParameterPrototype CapabilityStatus
Minimum Order Quantity1 pieceAvailable
Fastest Turnaround24 hours (express) / 72 hours (standard)Available
Board Size Range10mm × 10mm – 500mm × 500mmAvailable
Layer Count Range1 – 20 layersAvailable
Component Sourcing TurnaroundSame-day – 3 business days on common partsAvailable
Small-Reel / Cut-Tape SourcingAvailable — no full-reel purchase requiredAvailable
BOM / Gerber Review TurnaroundWithin 4 working hoursAvailable
Assembly TechnologySMT, THT, mixed, fine-pitch hand-solderAvailable
First Article InspectionIncluded on every prototype buildAvailable
Re-spin / Iteration SupportRush rebuild within 24 – 48 hoursAvailable
Bridge-to-ProductionDirect scale-up path, DFM data carried forwardAvailable
Quality & Compliance

Speed doesn't mean skipping inspection.

Every prototype — even a single unit — is built under the same quality system as our production runs, with a documented first-article inspection report shipped alongside your board.

ISO 9001 : 2015
Third-party audited quality management
ISO 13485 : 2016
Medical device quality management
IPC-A-610 Class 2 / 3
Acceptability of electronic assemblies
J-STD-001
Soldered electrical & electronic assemblies
ANSI/ESD S20.20
Electrostatic discharge control program
RoHS / REACH Compliant
Full material declarations available

Testing & Inspection Methods

  • Incoming Component InspectionVerified before kitting, every build
  • 100% Automated Optical Inspection (AOI)Pre- and post-reflow on every board
  • X-Ray Inspection — BGA & Hidden JointsAvailable on request for fine-pitch parts
  • Flying Probe Electrical TestOpen / short verification without fixture cost
  • Functional TestAd-hoc test jigs built for prototype validation
  • First Article Inspection (FAI) ReportIncluded with every prototype shipment
  • Dimensional & Visual InspectionManual verification against Gerber/BOM
  • Design-Iteration LogTracks changes across re-spins for traceability
Case Studies

Prototype programs we've delivered

Real fast-turn builds — from first spin to production handoff.

Medical · Wearable Device

Three Design Iterations in Two Weeks

A wearable-device startup needed three board re-spins to finalize sensor placement ahead of a clinical trial deadline, each build turned in 24 hours.

3rev
Design iterations
24h
Per-build turnaround
2wk
Total elapsed time
Outcome

Final design locked and clinical trial units delivered on schedule. The customer's team credited the fast re-spin loop with saving roughly six weeks versus their previous supplier.

IoT · Sensor Node

DFM Catch Saves a Failed Build

Our DFM review flagged a footprint mismatch on a BLE module before assembly began, avoiding a wasted build cycle for an early-stage IoT hardware team.

4h
DFM turnaround
1pt
Issue caught pre-build
100%
First-pass on retry
Outcome

Corrected footprint resolved before parts were ordered, saving an estimated 5 days and the cost of a scrapped component order.

Robotics · Motor Controller

Prototype-to-Production Bridge

A robotics startup validated their motor-controller design through four prototype spins, then scaled directly to a 5,000-unit production run with the same supplier.

4rev
Prototype spins
5k
Units in production
0d
Re-sourcing delay
Outcome

Production quote turned around in 24 hours using the validated BOM and DFM data — no re-review cycle and no supplier switch required to scale.

Why HanSphere

Why hardware teams
prototype with us.

Early-stage development is defined by speed and iteration. Our process is built around both — without cutting corners on quality when it's time to scale.

24h
Fastest turnaround

Speed when your schedule can't slip

Dedicated prototype lines and an express 24-hour assembly option mean a design change today can be a working board on your bench tomorrow.

1pc
Minimum order quantity

Build exactly what you need, nothing more

No panel minimums, no full-reel component purchases. We support true 1-piece builds so early-stage teams aren't forced to over-order to justify a run.

4h
DFM/DFA turnaround

Real engineers reviewing your design

Every submission gets a genuine DFM/DFA review from our engineering team — not just an automated rules check — with feedback returned in hours, not days.

1
Prototype to production

One supplier from first spin to volume run

No re-qualification, no re-sourcing and no re-DFM when you're ready to scale — your validated design and BOM data move straight into a production quote.

FAQ

Frequently asked questions

Common questions about prototype and NPI assembly, turnaround times and scaling to production.

Our express option is 24 hours from approved Gerbers/BOM and available component stock to shipped board, for common through-hole and SMT builds. Standard prototype turnaround is 72 hours. Boards using speciality laminates or components with longer sourcing lead times are quoted individually.

No. We accept orders as small as a single assembled unit. There's no panel minimum and no requirement to order more boards than your project actually needs at this stage.

Yes. We source in small-reel and cut-tape formats wherever the manufacturer or distributor supports it, so you don't need to buy a full reel of 3,000 parts for a one-off build. Where a part is only available in full-reel quantity, we'll flag it during the DFM/BOM review so there are no surprises.

Re-spins are treated as priority builds. Submit your updated Gerbers/BOM referencing the original order, and we'll turn the rebuild around in 24–48 hours. Our engineers also compare the new revision against your previous DFM notes to confirm earlier issues were resolved.

Yes, a first-article inspection report is included with every prototype build at no extra charge. It documents dimensional checks, component placement verification against your BOM, and AOI results, giving you a written record to support design-verification testing or investor/customer reviews.

Yes — this is a core part of our service. Once your design is validated, we carry your approved DFM data, BOM and process notes directly into a production quote, typically returned within 24 hours, with no need to re-qualify the design or switch suppliers.

Get a Quote

Start your prototype
build today.

Upload your files and our engineering team will return a free DFM/DFA review and quote within 4 working hours — with same-day scheduling available for urgent projects.

  • Free DFM/DFA review included with every enquiry
  • NDA signed on request — standard practice
  • 1-piece minimum order quantity
  • Response within 4 working hours
  • Direct bridge to production once validated
Request Prototype Assembly Quote All files encrypted · Max 80MB per upload · NDA available
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